GasificationGasification of of ORIMULSIONORIMULSION®:®:Synergism of the TwoSynergism of the Two
TechnologiesTechnologies
Presented in the 2001 Gasification Technologies ConferenceSan Francisco, October 7-10 2001
ORIMULSION® compared toother fuels ORIMULSION® compares
favourably to competing fuelssuch as Coal or Fuel Oil:
•Liquid fuel handling facilities.•Optimum combustionconditions.
•Base load operation at highreliability and load factors.
•Modern flue gas cleaningtechnology:
• ESP - low PM outlet, ashto metals recovery.
• deNOx - low NOxburners, OFA or SCR.
• FGD - wallboard qualitygypsum for sale.
Analysis Units ORIMULSION® Heavy BituminousFuel Oil Coal
Gross CalorificValue (HHV)
MJ/kg 30,2 43 25 - 28
Net Calorific Value(LHV)
MJ/kg 27,8 40 23 - 26
Carbon % (w/w) 61,8 86 60 - 65Hydrogen % (w/w) 10,8 11 3 - 5Sulphur % (w/w) 2,85 1 - 4 0.4 - 2.5Nitrogen % (w/w) 0,5 0.2 - 0.4 1 - 1.5
Ash % (w/w) 0,07 <0.1 5 - 20Magnesium mg/kg 6,0 1 - 3 1 - 50
Nickel mg/kg 75 20 - 50 0.5 - 50Sodium mg/kg 12 0 - 30 1 - 30
Vanadium mg/kg 320 30 - 300 2 - 100Density at 15 ºC g/ml 1.0090 0.93 - 1.03 -Viscosity at 30 ºC mPa.s 230 2.400 -
Water Content % (w/w) 29,0 <0.5 5 - 20Flash Point ºC >95 >60 -Pour Point ºC +3 <30 -
What is ORIMULSION®?
A stable emulsion of bitumen in water with handling propertiessimilar to fuel oil
==++
BITUMEN
30 % 100 %70 %
WATER ORIMULSION®
ADDITIVES SURFACTANTS
VENEZUELA
ORINOCO RIVER
ORINOCO BELT : 54,000 KmORINOCO BELT : 54,000 Km22
41 x 1041 x 1099 metric tons metric tons
World’s largest bitumen reservesWorld’s largest bitumen reserves
For practical purposes the Orinoco Belt reserves areinexhaustible...
(Pro
duct
ion
Rat
e)M
illion
bar
rels
per
day
Years (R/P)0 100 200 300 400 500
1.5
2.0
4.0
5.0
A general view of the ORIMULSION® chainbefore export
Gas
Diluent
SeparationFlow Station Mixing
WaterSediments
Sodium
Water
Pipeline (300 km)
Surfactant
Marine Terminal
Storage
Wells
MORICHAL JOSE
ORIMULSION® canbe used to generateelectricity in anumber of ways
STEAMTURBINESSTEAMTURBINES
DIESELENGINESDIESELENGINES
IGCCIGCC
ORIMULSION® experienceClients experience can besummarized as follows:
•Lower NOx emissions than Coaland Fuel Oil at the sameoperating conditions.
•Excellent combustionproperties, producing less than0.2% of unburned carbon.
•CO2 emissions wereconsiderably lower than Coaland similar to those from FuelOil.
•SO2 and particulate emissionscould be controlled usingconventional equipment.
But...A new formula had to bedeveloped mainly because of thetwo following reasons:
•Environmental concernregarding some detergentagents, specially thosecomposed by nonylphenolethoxilates, launched aresearch effort to substitute thesurfactant used inORIMULSION®.
•Some improvements weredesirable to adapt the fuel tothe growing high requirementsof a competitive market.
Premises for a new formula•The new formulation should nothave a nonylphenol surfactant tocomply with the environmentalrequirement.•New formulation should meanimprovements in current plantsperformance in terms of:
•Environmental emissions.•Boiler performance.•Minimize de-rate.•Lower perceived potential (andreal) corrosion.
ORIMULSION®400
Droplet sizedistribution is oneof the mostimportantcharacteristic inORIMULSION®manufacturing andhandling.Typical mediandroplet size isaround 14,5µ.
TYPICAL DROPLET SIZE DISTRIBUTION DURING MANUFACTURE
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2.0
4.0
6.0
8.0
10.0
12.0
0.10 1.00 10.00 100.00 1000.00Particle size (um)
%
ORI400ORI100
600 cP215 cP
ORIMULSION® hasnon-Newtonianbehaviour properties.Viscosity depends onshear rate and ontemperature.New ORIMULSION®formula has lowerviscosity thanprevious.
0
200
400
600
800
1000
1200
0 50 100 150 200
Shear Rate, s-1
App
aren
t Vis
cosi
ty @
30°
C, m
Pa.s
ORIMULSION 100
ORIMULSION 400
0100200300400500600700800
0 50 100 150 200Shear Rate, s-1
App
aren
t Vis
cosi
ty, m
Pa.s
T= 30°CT= 50°C
Maximum recommended period 4months.
Summary of best operation criteria.Summary of best operation criteria.Inventory control First-in first-out basis.
Storage period
Temperature Recommended storage temperaturerange: 20 ° to 40°C.
Heating Maximum wall temperature ofheating element: 70°C (158°F).
Unpumpable volume
Not greater than 1 % of tank capacity.
1. Water in the Emulsion will evaporate.2. Volatile components of thebitumen will begin to evaporate andignite.
3. Any water droplets within thebitumen will expand and break-up thedroplet even further.4. The fuel will burn-out leaving onlythe inorganic ash.
ORIMULSION® combustionLiquid fuel handling facilities.Conventional steam boilers (HFO/coal design ornew build) and IGCC.Optimum combustion conditions (low O2 / NOx /PM).Thermal efficiency similar to HFO operation.Excellent load following and turn-down capabilities.Base load operation at high reliability and loadfactors.Modern flue gas cleaning technology:
ESP - low PM outlet, ash to metals recovery.deNOx - low NOx burners, OFA or SCR.FGD - wallboard quality gypsum for sale.
Low cost, clean electricity.
ASNÆS 5 Corrosion probesunder a commercial testORIMULSION® deposits corrosionrate have a parabolic profile. Theseresults are associated with theformation of a protective oxide scaleindicating that ORIMULSION® has anacceptable corrosion rate in the longterm, without the need to addmagnesium in-fuel.
0200400600800
1000
(50 hrs) (300 hrs) (700 hrs)Temperature (°C)
nmh-1
ORIMULSION® combustion
Asnæs unit 5 - Foulingfactors
•From the boiler datacompiled during the test in1998 a boiler modeling wasperformed to determinefouling factors.
•The one dimensional modelestimated that foulingresistances forORIMULSION®400 shouldbe around half of the valuespreviously gotten when firingORIMULSION®100.
Fouling factors
•Lower temperature banks fouling was found to be practicallynegligible compared to the levels obtained when firingORIMULSION®100.
Boiler inspectionAsnæs Unit 5 was inspected after 1100 hrs of operation usingORIMULSION®400 as main fuel without magnesiuminjection, the inspection was carried out during September26th & 27th.
•Furnace slagging appearance and amount were similar forboth formulations. However,ORIMULSION ®400 furnacefouling was considerably less.
•No indication of apparent corrosion was found in the hightemperature boiler zone, which validates the results obtainedfrom the corrosion probes.
ORIMULSION®100 ORIMULSION®400
ORIMULSION®400ORIMULSION®100
ENEL Brindisi Sud Plant Unit 1 fouling factors
Fouling factors estimated by ENEL using their PROATES®Unit 1 model, indicated (as in Asnæs case) heat resistancesof about half when ORIMULSION®400 is compared to itspredecessor.
Source: ENEL report “Experience firing Orimulsion® in a 660 MWe Power Plant
Firing ORIMULSION®400.Firing ORIMULSION®100 with noadditional soot blowing facilities.
Brindisi Sud Unit N°1 Superheater 1 firing ORIMULSION®
Orimulsion®400 Fouling - Summary
• Fouling reduction proofs have been consistently found inall the installation firing Orimulsion®400.
• Estimated fouling factors are in agreement with thosemeasured with a deposition probe.
• The reduction in fouling resistance relative toOrimulsion®100 is around 50%.
• This reduction is due to the morphologic differences foundbetween both formulation ashes.
Background• Brindisi units are 660 MWe once-through boilers, designed by FrancoTosi SpA.
• The units are fitted with 56 burners ina front/rear arrange.
• Each unit is equipped with over fireair (OFA) ports and selective catalyticreduction (SCR) to control NOxemissions.
• A FGD scrubber tower and a seven-field ESP are installed to control SO2emissions and PM, respectively.
• Brindisi Sud started operations usingORIMULSION®400 in November1999.
The lower excess oxygen used for ORIMULSION®firing indicates better combustion properties
SCR excess O2 vs Load for Orimulsion® and Fuel Oil
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0 100 200 300 400 500 600 700LOAD (MWe)
SCR
exc
ess
O2
%
SCR O2 excess side A Orimulsion SCR O2 excess side B OrimulsionSCR O2 excess side A Fuel Oil SCR O2 excess side B Fuel Oil
SCR excess O2 vs Load for Orimulsion® and Coal
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0 100 200 300 400 500 600 700 800LOAD (MWe)
SCR
exc
ess
O2
%
SCR O2 excess side A Coal SCR O2 excess side B CoalSCR O2 excess side A Orimulsion SCR O2 excess side B Orimulsion
When compared on thesame bases Fuel Oil andORIMULSION® producesthe same amount of NOx.
Under the same operatingconditions ORIMULSION®produces 40 % less NOxthan Coal.
S C R in le t c o n c e n t r a t io n v s L o a dO r im u ls io n ® a n d F u e l O i l
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1 0 0 0
0 1 0 0 2 0 0 3 0 0 4 0 0 5 0 0 6 0 0 7 0 0
L O A D ( M W e )
NO
x co
ncen
tratio
n (m
g/N
m3)
S C R in le t N O x O r im u ls io n ® w i t h O F A S C R in le t F u e l O i l
S C R in le t c o n c e n t r a t io n v s L o a d fo r O r im u ls io n ® a n d C o a l w i th O F A c o o l in g a i r
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1 0 0 0
0 1 0 0 2 0 0 3 0 0 4 0 0 5 0 0 6 0 0 7 0 0 8 0 0L O A D ( M W e )
NO
x co
ncen
tratio
n (m
g/N
m3)
S C R in le t N O x O r im u ls io n ® S C R in le t N O x C o a l
More scatter butslightly betterparticulate collectionefficiencies areobtained forORIMULSION® firingwhen compared toFuel Oil.
Stack PM concentration vs LOAD for Orimulsion® and Fuel Oil
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LOAD (MWe)
Stac
k co
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m3)
Paticulate Orimulsion® Particulate Fuel Oil
Brindisi Sud HighlightsWhen boiler performances are compared using Fuel Oil, Coal andORIMULSION®, the following facts are the most relevant:
•Lower excess oxygen used for ORIMULSION® firing.•Similar boiler outlet temperature obtained for ORIMULSION® andFuel Oil.
•ORIMULSION® and Fuel Oil performances are very similar in NOxand CO emissions. However, particulate levels are slightly lower forORIMULSION® despite of its relatively higher ash content.
•ORIMULSION® produces about 40% less NOx than Coal and similarvalues than Fuel Oil.
ORIMULSION® and IGCC
As derived from the previous presented data, theadvantages of the ORIMULSION® fuel in both combustionand environmental performances and its attractive priceformula makes ORIMULSION® a prime fuel for IGCC.
Gasification Test In Texaco Montebello Pilot Plant
In 1989, a ORIMULSION® gasification test took place in the TexacoMontebello pilot plant facilities in California.
Approximately 144 tons of ORIMULSION® were gasified in a combinedrun time of nine days.
A Variable Run Test for investigating different process variables and aExtended Run Test of over four hours were conducted.
The main objectives of the tests were:
•To demonstrate the suitability of ORIMULSION® as feedstockfor the Texaco Gasification Power System.
•To demonstrate sustained operation of the power plant usingORIMULSION®.
•To obtain process design and analytical data.
Conclusions From The Texaco Montebello Test
• ORIMULSION® is an attractive feedstock for the Texaco GasificationPower Systems (TGPS) from the efficiency, environmental andeconomical standpoints.
• The water contained in the ORIMULSION® mixture serves as atemperature moderator for the Texaco Gasification Process (TGP),thus making ORIMULSION® a very desirable feedstock. Thisminimize the plant's overall water requirements.
• Excellent performance and unit operability were demonstrated duringthe gasification tests. Data obtained during the tests validatedTexaco's performance estimates for commercial design.
Conclusions From the Texaco Montebello Test (Cont)
• ORIMULSION® handling facilities for commercial TGPS units can bereadily designed taking into account BITOR's handling guidelines.
• Compared with the gasification of typical coal/water slurries,ORIMULSION® gasification results in better thermal efficiencies andhigher yields of product gas per units of dry fuel and oxygen.
• TGPS, plants can be designed with feedstock flexibility to handleORIMULSION® and/or other materials such as coal/water slurries.
Plant availability for different fuelsThe purpose of the study is to determine the influence of the plantavailability in the final electricity cost. For this, a number of diferentcomparisons were made, including:
•Conventional cycle (Coal and ORIMULSION® fueled).•Natural Gas Combined Cycle NGCC.•Integrated Gasification Combined Cycle IGCC.
•All estimations are based on a 500MW net output power plant size.•All plants must satisfy environmental regulations, specially the SO2limit of 400 mg/Nm3.
All projects are based on:•Projects life: 20 years•Equity: 30% Rate of interest:
•Equity: 15 %/year.•Debt: 10 %/year.
Plant availability for different fuels (cont)Conventional Cycle drum-type boiler with 38%thermal efficiency:
Coal:Capital cost: 1050 US$/kW.Fuel cost (delivered): 1.70 US$/MMBtu.Flue Gas Desulfurization unit (FGD) no required.Fuel Properties:•HHV: 6671 kcal/kg.•Ash: 14%.•Sulfur: 0.8 % (w/w).
ORIMULSION®:Capital cost: 900 US$/Kw (same as a Fuel Oil Plant).Fuel cost (delivered): 1.74 US$/MMBtu.FGD required.Fuel Properties:•HHV: 7218 kcal/kg.•Ash: 0.07%.•Sulfur: 2.85 % (w/w).
Plant availability for different fuels (cont)Natural Gas Combined Cycle (NGCC) (F type gas turbine in a combinedcycle with 55% thermal efficiency)
Natural Gas:Capital cost: 600 US$/kW.Fuel cost (delivered): 3.80 US$/MMBtu.
Integrated Gasification Combined Cycle (IGCC) (oxygen-blown typegasifier with 42% thermal efficiency).
ORIMULSION®:Capital cost: 1080 US$/kW (same as a Fuel Oil plant).Fuel cost (delivered): 1.74 US$/MMBtu.
This chart shows that NGCChas the lower busbar cost forany conventional total plantcost evaluated in thesensibility, which is in linewith the literature on thisissue.
Total plant cost analysis
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0 200 400 600 800 1000 1200 1400 1600 1800Total plant cost (US$/kW)
Bus
bar C
ost (
cent
s/kW
h)
NGCC-GAS Orimulsion - Conv. Coal-Conv.
An IGCC firing ORIMULSION®produces a marginal lower busbarcost than a conventional plantfiring ORIMULSION® at the samefuel price.A conventional steam plant firingCoal at the same fuel price willproduce a much higher busbarcost.For the same busbar cost (fixed at3,87 UScents/kWh for IGCC firingORIMULSION® at a fuel price1,74 US$/MMBtu), a priceincentive must be placed on bothCoal and ORIMULSION®, under aconventional steam generationplant, and also on gas prices in aNGCC plant.
Fuel cost analysis
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0,00 1,00 2,00 3,00 4,00 5,00 6,00Fuel Cost (US$/MMBtu)
Bus
bar C
ost (
cent
s/kW
h)
NGCC-GAS Orimulsion - Conv. IGCC- Orimulsion Coal-Conv.
The minimum requiredavailability for a IGCC projectfiring ORIMULSION® is lowerthan 90%.For ORIMULSION(R) furtherimprovements in terms ofavailability can be obtained,which is the case of a liquid fuel,and a lower busbar cost can beexpected.
Availability analysis
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75,0 80,0 85,0 90,0 95,0 100,0Plant availability (% /year)
Bus
bar C
ost (
cent
s/kW
h)
NGCC-GAS Orimulsion - Conv. IGCC- Orimulsion Coal-Conv.
Current solid fedIGCC availability
Conclusions
• Bitumen reserves for manufacturing ORIMULSION® are for practicalpurposes, inexhaustible. This reservoir will play an important role inthe world energy scenario in the years to come.
• ORIMULSION® has several advantages when compared againstCoal not only from the handling point of view, but from thecombustion and environmental performance as well. ORIMULSION®has an enhanced Fuel Oil like performance, due to the excellentcombustion properties linked to both the low excess O2 required forcombustion and excellent atomizing properties. ORIMULSION®environmental performance is comparable to Fuel Oil usingconventional emission abatement equipment.
Conclusions (cont)
• An IGCC firing ORIMULSION® produces a lower busbar cost than aconventional plant firing ORIMULSION® at the same fuel price,making the development of ORIMULSION® based IGCC projectsmore attractive than conventional generation, allowing space forfurther improvements as confidence on ORIMULSION® is gained. Onthe other hand, a conventional steam plant firing Coal at the samefuel price will produce a much higher busbar cost.
• For the same busbar cost (fixed at 3,87 UScents/kWh for IGCC firingORIMULSION® at a fuel price 1,74 US$/MMBtu), a price incentivemust be placed on both Coal and ORIMULSION® under aconventional steam generation plant and on gas price in a GTCC aswell.
Conclusions (cont)
• The minimum required availability for a IGCC project firingORIMULSION® is lower than 90%,%, which already has been reportedfor liquid fuel IGCC. If a higher availability as reached with otherliquid fuel applications can be obtained with ORIMULSION®, furtherimprovements can be obtained and a lower busbar cost can beexpected.
End of presentation
